A Lightweighting Solution for Converting an Aluminum Bracket to Plastic Using Long Fiber Thermoplastic Technology 2014-28-0010

This breakthrough development involves material conversion from aluminum die cast to polypropylene long fiber thermoplastic (40% long glass filled) for a two wheeler bracket of a leading automotive OEM.

The plastic bracket was developed working in collaboration with the molder, glass supplier, technology collaborator and the OEM. The new part needed to be designed lighter in weight, easier to process and suitable for painting, outdoor exposure and stringent dynamic conditions. The scope of this study includes the evaluation of the new material from different viewpoints and comparison of the same with the existing material.

The submission will go through the intricate analyses carried out in the development process and highlight the key advantages over aluminum. Studies will include static and dynamic analysis, fiber orientation studies, gate location studies, etc.